Additive dispersing filter and method of making

ABSTRACT

A filter, comprising: a housing defining an inlet fluid opening and an outlet fluid opening, the inlet fluid opening and the outlet fluid opening defining a fluid path through the filter; a filter element disposed inside the filter housing, the filter element being disposed in the flow path such that fluid flowing through the flow path must pass through the filter element; and a dispersement device disposed within the housing, the dispersement device comprising a housing having at least one chamber for an additive disposed within the at least one chamber, the dispersement device further comprises a metering opening that is sealed with an oil soluble material the metering opening being in fluid communication with the at least one chamber when the oil soluble material is removed from the metering opening.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/343,828 filed Dec. 24, 2008, which is a divisional application ofU.S. patent application Ser. No. 11/846,265 filed Aug. 28, 2007, whichclaims the benefit of U.S. Provisional Patent Application 60/840,661filed Aug. 28, 2006 the contents each of which are incorporated hereinby reference thereto.

The present application is also related to the following patentapplications: Ser. No. 10/352,344, filed Jan. 27, 2003; Ser. No.09/867,973, filed May 30, 2001; Ser. No. 09/566,034 filed May 8, 2000;U.S. patent application Ser. No. 10/863,581, filed Jun. 8, 2004; U.S.patent application Ser. No. 11/488,466, filed Jul. 18, 2006; U.S. patentapplication Ser. No. 11/533,649 filed Sep. 20, 2006; U.S. patentapplication Ser. No. 11/845,042, filed Aug. 25, 2007; and U.S. patentapplication Ser. No. 11/854,043, filed Aug. 25, 2007, the contents eachof which are incorporated herein by reference thereto.

BACKGROUND

The present invention relates to a filter for a fluid and a method formaking the same.

Many different types of fluid filters are known. Most such filters use amechanical or ‘screening’ type of filtration, with a porous filterelement disposed therein. The oil is repeatedly cycled through thefilter element to remove impurities.

In the oil filtration art, it is well known that normal operation of aninternal combustion engine, particularly a diesel engine, results in theformation of contaminants. These contaminants include, among others,soot, which is formed from incomplete combustion of the fossil fuel, andacids that result from combustion. These contaminants are typicallyintroduced into the lubricating oil during engine operation, and tend toincrease oil viscosity and generate unwanted engine deposits, leading toincreased engine wear.

The conventional solution to these problems has been to place variousadditives into lubricating oils, during their initial formulation. Inorder to combat soot-related problems, many conventional lubricatingoils include dispersants that resist agglomeration of soot therein.These work well for a short period, but may become depleted.Additionally, due to the solubility and chemical stability limits ofthese dispersants in the oil, the service lives of the lubricating oiland the oil filter are less than optimal.

In order to counteract the effects of acidic combustion products, manyconventional motor oils include neutralizing additives known asover-based detergents. These are a source of TBN (total base number),which is a measure of the quantity of the over-based detergent in theoil. The depletion of the TBN is an important limiting factor for manyinternal combustion engines, and in particular for heavy-dutyapplications with diesel engines.

In order to improve engine protection and to combat other problems,conventional lubricating oils often include one or more furtheradditives, which may be corrosion inhibitors, antioxidants, frictionmodifiers, pour point depressants, detergents, viscosity indeximprovers, anti-wear agents, and/or extreme pressure additives. Theinclusion of these further additives may be beneficial; however, withconventional methods, the amount and concentration of these additivesare limited by the ability of lubricating oils to suspend theseadditives, as well as by the chemical stability of these additives inthe oil.

While the known filters are usable for their intended purposes, therelease of supplemental additives from the known filters often takesplace either immediately after installation or more rapidly than isneeded for protecting the oil. Subsequently, after some time haselapsed, there may be little or no additive left in the filter.

Another problem with many of the known filter designs is that beneficialadditives are added to the oil before the oil is mechanically filteredthrough a filter element. As a result, when the oil is mechanicallyfiltered, some of the beneficial additives that have just been added maybe immediately filtered out.

In addition, and due to emission regulations that went into effectduring 2002, heavy/medium duty diesel engines have been forced to run atconditions that deteriorate the crank case lube oil additive package atan accelerated rate. This leads to a reduction in the number of miles atruck can travel before the crank case oil needs to be changed, causingincrease in downtime and operating costs of the truck, thus a reductionof profits for the owner.

Therefore it is desirable to provide a filter having an additiveincorporated therein, wherein the additive is slowly released over theuseful life of the filter. It is also desirable to provide an oil filterwhich could extend the useful life of engine oil so as to allow a userto extend the time interval between oil changes of an engine.

SUMMARY OF THE INVENTION

An additive dispersing filter and method of making is provided.Exemplary embodiments provide a filter, comprising: a housing definingan inlet fluid opening and an outlet fluid opening, the inlet fluidopening and the outlet fluid opening defining a fluid path through thefilter; a filter element disposed inside the filter housing, the filterelement being disposed in the flow path such that fluid flowing throughthe flow path must pass through the filter element; and a dispersementdevice disposed within the housing, the dispersement device comprising ahousing having at least one chamber for an additive disposed within theat least one chamber, the dispersement device further comprises ametering opening that is sealed with an oil soluble material themetering opening being in fluid communication with the at least onechamber when the oil soluble material is removed from the meteringopening.

In another exemplary embodiment a filter is provided, the filtercomprising: a housing defining an inlet fluid opening and an outletfluid opening, the inlet fluid opening and the outlet fluid openingdefining a fluid path through the filter; a filter element disposedinside the filter housing, the filter element being disposed in the flowpath such that fluid flowing through the flow path must pass through thefilter element; a dispersement device disposed within the housing, thedispersement device comprising a housing having a first chamber and asecond chamber, the second chamber being sealed from the first chamberby a pair of dividing walls, the dispersement device being secured tothe filter element and a central opening of the filter element and thedispersement device are in fluid communication with the outlet fluidopening; a first additive disposed within the first chamber; a secondadditive disposed within the second chamber; a first metering openingthat is sealed with an oil soluble material the first metering openingbeing in fluid communication with the first chamber when the oil solublematerial is removed from the first metering opening; and a secondmetering opening that is sealed with an oil soluble material the secondmetering opening being in fluid communication with the second chamberwhen the oil soluble material is removed from the second meteringopening.

In another exemplary embodiment a method of supplying an additive in anoil filter is provided, the method comprising: forming a dispersementdevice housing with a first chamber and a second chamber, the secondchamber being sealed from the first chamber by a pair of dividing walls;sealing a first metering opening with an oil soluble material the firstmetering opening being in fluid communication with the first chamberwhen the oil soluble material is removed from the first meteringopening; sealing a second metering opening with an oil soluble materialthe second metering opening being in fluid communication with the secondchamber when the oil soluble material is removed from the secondmetering opening; disposing a first liquid additive within the firstchamber; disposing a second liquid additive within the second chamber;sealing the dispersement device housing with a cap, the cap beingconfigured to seal the first chamber and the second chamber within thedispersement device housing; and securing the dispersement devicehousing to a filter element of the filter, the filter element and thedispersement device defining an outlet fluid opening, such that fluidflowing into and out of the filter must pass through the filter elementand into the outlet fluid opening and the cap is located between thefilter element and the dispersement device housing.

Exemplary embodiments are also directed to an additive dispersing memberconfigured to be received within an oil filter.

The above-described and other features are appreciated and understood bythose skilled in the art from the following detailed description,drawings, and appended claims.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an oil filter constructed in accordancewith an exemplary embodiment of the present invention;

FIG. 2 is an exploded perspective view of an oil filter constructed inaccordance with an exemplary embodiment of the present invention; and

FIGS. 3A-4C are views illustrating an additive cartridge for use inexemplary embodiments of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In accordance with exemplary embodiments of the present invention, afilter and method of making a filter is disclosed. In an exemplaryembodiment the filter will be comprised of an additive cartridge ordispersement device for providing a means for introducing an additiveinto oil being filtered by the filter. In addition, an additivecartridge and method of making is also disclosed wherein the cartridgeprovides a means for retaining an additive for dispersement into the oilover a period of time.

Referring to FIGS. 1 and 2, there is shown an oil filter 10 according toa first exemplary embodiment of this invention. The oil filter generallyincludes a hollow cylindrical housing 12 which defines a hollow chamber14 therein, a porous, mechanical filter element 15 within that chamber,and a centrally located additive cartridge or dispersement device 18,also retained inside the housing chamber 14.

The housing also includes a base plate 24 sealingly attached to the caseor housing. A foraminous center tube may, optionally, be provided withinthe filter housing to supportively reinforce the mechanical filterelement thereon.

The housing base plate includes a plurality of inlet ports 28 formedtherethrough and arranged in a circular pattern. The base plate alsoincludes a central outlet port 30. The outlet port has a plurality offemale threads formed therein, to allow rotatable mounting of the filteron an externally threaded hollow tubular fitting on an engine block (notshown). An annular external seal or gasket 32 fits engagingly into agroove formed at the bottom surface of the base plate, to resist oilleakage outwardly from the base of the filter.

A gasket 36 is disposed between additive cartridge or basket 18 and themechanical filter element.

In the depicted embodiment of FIGS. 1-2, the mechanical filter element15 includes a conventional cylindrical member made of accordion-pleatedfilter paper having a center tube or central opening 17 that allowsfluid filtered by the mechanical filter element to exit the filterthrough central outlet port 30. Alternatively, the filter element may bemanufactured in accordance with the teachings of U.S. provisional patentapplication Ser. No. 11/533,649 filed Sep. 20, 2006; and/or U.S. patentapplication Ser. No. 11/845,042, filed Aug. 25, 2007; the contents eachof which are incorporated herein by reference thereto.

The additive cartridge includes a housing portion 40 having a firstchamber 42 and a second chamber 44. First chamber 42 is separated fromsecond chamber 44 by a pair of dividing walls 46 and 48. In oneembodiment a liquid additive is disposed in chambers 42 and 44. Ametering opening 50 is provided to allow the additive of first chamber42 to pass therethough during usage of the filter. In accordance with anexemplary embodiment metering opening has a diameter of approximately20/1000 of an inch. Thus, the additive is slowly metered out over theuseful life of the filter. Of course, metering openings greater or lessthan the aforementioned opening are contemplated to be within the scopeof exemplary embodiments of the present invention. Furthermore, a singleopening 50 may be provided or multiple openings may be provided forfluid communication to chamber 42.

Similarly a metering opening 52 is provided to allow the additive ofsecond chamber 44 to pass therethough during usage of the filter. Inaccordance with an exemplary embodiment metering opening 52 also has adiameter of approximately 20/1000 of an inch. Thus, the additive isslowly metered out over the useful life of the filter. Of course,metering openings greater or less than the aforementioned opening arecontemplated to be within the scope of exemplary embodiments of thepresent invention. Furthermore, a single opening 52 may be provided ormultiple openings may be provided for fluid communication to chamber 44.

Each metering opening is sealed with an oil soluble material, whichdissolves when the filter is used. In one embodiment, the oil solublematerial may be a wax and the additive disposed in chambers 42 and 44 isa liquid. Alternatively, and if applicable, the oil soluble material maycomprise the additive disposed in the chambers 42 and 44 if the additiveis a non-viscous material (e.g., gel).

In accordance with an exemplary embodiment, chamber 42 comprises oneadditive and chamber 44 comprises another, each being distinct from oneanother. For example and in one non-limiting embodiment one additive isan antioxidant and the other is an over based detergent.

Of course, other additives are contemplated in accordance with exemplaryembodiments of the present invention. In addition, the housing 40 may beconfigured to have multiple chambers and multiple metering holes.Alternatively, the housing may be configured to have only a singlechamber and a single metering hole or plurality of metering holes thusonly one additive is provided by the single chamber of the additivecartridge or dispersement device.

In one non-limiting exemplary embodiment, the additives are liquid inform and the oil soluble sealing material over openings 50 and 52 is awax, which melts away during use thereby uncovering the metering hole.In other words when the engine oil reaches operational temperature theoil becomes hot enough to melt the wax and then the additives aredispersed into the oil. Moreover, the dimension of the metering openingor openings slowly disperses the additive over time or over the usefullife of the filter. Alternatively, the additives are gels or pellets andthe gel itself may comprise the sealing material.

As illustrated in FIG. 3 second chamber 44 is larger than chamber 42thus, structural ribs 56, if necessary, are located in the secondchamber. Alternatively, second chamber 44 is constructed withoutstructural ribs 56. Accordingly, a larger amount of additive can beplaced in the second chamber as opposed to the first chamber. Structuralribs 56 are angled such that they will not interfere with the fluid flowof the additive from the chamber. In other words, the structural ribs atone point will terminate at a bottom surface of the housing (e.g.,opposite cap 70), which is proximate to the metering opening(s).Furthermore and as applications require the size of chambers 42 and 44may vary as the required amounts of the additives varies. For exampleand in one non-limiting embodiment, one additive is an antioxidant andthe other is an over based detergent and if required, a larger amount ofthe antioxidant additive may be supplied in the larger chamber asopposed to the over based detergent in the smaller chamber. Of course,the amounts of additives, types and size and number of chambers mayvary. For example, a larger amount of over based detergent may besupplied in the larger chamber as opposed to the antioxidant additive inthe smaller chamber. Again, any one of the additives mentioned hereinmay be disposed in the chambers in various amounts.

In addition, the housing has neck portions on either side of the housingfor engagement with the outlet opening of the base plate and the centeropening of the filter media. This will allow for ease of placement aswell as providing a fluid seal for fluid transfer through thedispersement housing.

In accordance with an exemplary embodiment of the present invention, thehousing will have a neck portion 81 that depends away from the housingsuch that when the same is fluidly sealed to the outlet opening of thebase plate 24 a gap is maintained between a surface of the additivecartridge and the inlet openings 28 of the base plate in order allowfluid flow over the top of the additive cartridge and then along theside walls of the cartridge containing openings 50 and 52 and then intofilter media 15 and then ultimately through the center opening 17 andthe outlet path 80, which is in fluid communication with opening 30 sothat filtered oil or fluid can exit the filter. Accordingly, and asfluid flows past metering openings 50 and 52 additive stored in thedispersement device is released into fluid or oil flowing past theadditive cartridge or dispersement device.

It being understood that the outer periphery of the additive cartridgeand the filter media are slightly smaller than the inner dimension ofthe housing of the filter such that fluid flowing into the inletopenings 28 passes through the gap between the top of the additivecartridge and the base plate and then into a gap or flow path defined bythe outer periphery of the housing of the additive cartridge and theouter periphery of the filter media and the inner dimension of thehousing of the filter, wherein the fluid then flows into the filtermedia and back out of the filter housing via the outlet path defined byopenings 17, 80 and 30. In one non-limiting exemplary embodiment, theouter periphery of the filter media and the housing of the additivecartridge are substantially the same thus making insertion of the filtermedia and the dispersement device or additive cartridge into the housingsimple. Furthermore, there is no requirement to resize the filterhousing to accommodate the additive cartridge. For example, an existingfilter housing design without an additive cartridge may be used bysimply reducing the length of the filter media to accommodate for theheight of the additive cartridge.

The additive composition includes one or more additives which may beselected from the group including basic conditioners, corrosioninhibitors, metal deactivators, antioxidants, dispersants, frictionmodifiers, oil stabilizers, pour point depressants, detergents,viscosity index improvers, anti-wear agents, extreme pressure additives,mixtures of the above additives, and/or other known beneficialadditives.

The basic conditioner of the additive cartridge, where used, ispreferably a basic salt selected from the group consisting of lithiumhydroxide, calcium carbonate, potassium carbonate, potassiumbicarbonate, aluminum dihydroxy sodium carbonate, magnesium oxide,magnesium carbonate, zinc oxide, sodium bicarbonate, sodium hydroxide,calcium hydroxide, potassium hydroxide, and mixtures thereof

Of course, other compositions may be used as the additive(s).

FIG. 4 illustrates a cap 70 that is configured to be secured to housing40 after the additives are disposed therein. In accordance with anexemplary embodiment of the present invention cap 70 is circular or diskshape with an opening 72 configured to receive a neck portion 74 of thehousing therein. Of course, other configurations are contemplated to bewithin the scope of exemplary embodiments of the present invention. Asillustrated, the neck portion 74 will extend past cap 70 to provide afeature for receipt into opening 17 of an end cap of the filter media.Cap 70 in one exemplary embodiment will have an annular feature 76 forreceipt in an annular groove 78 of the housing. In one embodimentfeature 76 will provide a heat staking member for securement of the capto the housing by a vibration welding method, ultrasonic welding methodor spin welding. Alternatively or in addition to the aforementionedwelding techniques an adhesive is used to secure the feature into thegroove. Similar features and methods may be employed to secure aperipheral end of the cap to the outer walls of the housing.

In accordance with an exemplary embodiment a method of supplying anadditive in an oil filter is provided, the method comprising: forming adispersement device housing with a first chamber and a second chamber,the second chamber being sealed from the first chamber by a pair ofdividing walls; sealing a first metering opening with an oil solublematerial the first metering opening being in fluid communication withthe first chamber when the oil soluble material is removed from thefirst metering opening; sealing a second metering opening with an oilsoluble material the second metering opening being in fluidcommunication with the second chamber when the oil soluble material isremoved from the second metering opening; disposing a first liquidadditive within the first chamber; disposing a second liquid additivewithin the second chamber; sealing the dispersement device housing witha cap, the cap being configured to seal the first chamber and the secondchamber within the dispersement device housing; and securing thedispersement device housing to a filter element of the filter, thefilter element and the dispersement device defining an outlet fluidopening, such that fluid flowing into and out of the filter must passthrough the filter element and into the outlet fluid opening and the capis located between the filter element and the dispersement devicehousing.

Accordingly, the housing is first filled with an additive in at leastone chamber and then the housing is sealed with a cap. Since thecartridge in one embodiment is disposed between the filter media and thebase plate 24 the housing is inverted so that cap 70 is disposed betweenthe end cap of the media and the housing of the additive cartridge.Alternatively and if the cartridge is disposed on the other side of thefilter media away from the end cap the cartridge may not need to beinverted during its installation.

Housing portion 40 and cap 70 of additive cartridge, dispersement deviceor basket 18 are configured to provide an outlet path 80, which is influid communication with opening 30 so that filtered oil or fluid maypass therethrough.

The material selected for the cartridge shell and cap is preferred to bea material which remains stable in a hot oil environment. Preferredmaterials are metals such as steel and oil-tolerant plastics such as,polyacetals and equivalents thereof The cartridge allows the beneficialadditive composition to be slowly released into the oil, therebyconditioning the oil in a metered manner over time.

By incorporating into the lube filter the needed additives, via theadditive dispersement device or additive cartridge, to reinforce theones that are depleted, the lube filter can help extend the effectivelife of the oil back to pre-2002 emission regulation intervals andbeyond. This is done by storing the required additive(s) in a storagebasket(s) or other equivalent devices that reside inside the oil filter.The basket(s) can be located in the center tube portion of themechanically active filter, above or below the mechanically activefilter element or any combination thereof The basket(s) may have asingle or multiple pockets that can store the required additive(s). Eachpocket will have a single or multiple holes to control the release rateof the additives that reside in each respective pocket. The number, sizeand location of the holes will be used to control the release rate ofthe additive(s). By properly controlling the release rate of theadditive the effectiveness of the additives can be enhanced. A sensormay also be incorporated into the dome of the filter that will monitoroil condition and provide real-time feedback to the owner or operator ofthe truck.

The additive baskets would preferably be made from injection moldedplastic. After the basket is molded the metering holes will be pluggedwith an oil soluble material capable of withstanding production andstorage conditions, but also being able to release during operation ofthe truck to allow the release of additives within the given pockets. Inproduction, after the metering holes are plugged the additive can befilled into each respective pocket. Once the additives have been putinto the pocket the basket will be completely sealed and is ready forassembly into the lube filter. The basket can be sealed by a gasket withadhesive on one side or a cap that is vibration welded, spin welded orglued to the basket housing. After the additive basket is assembled intothe lube filter, the lube filter is seamed up providing the finalproduct. The final product will fit the specified applications with nomodification to mounting parameters and will be installed in the samemanner traditional lube filters are installed. For example, in oneembodiment the housing of the dispersement device has a circularconfiguration and an outer periphery of the housing of the dispersementdevice is substantially similar to an outer periphery of the filterelement such that the dispersement device is easily secured to thefilter element and the two items are secured into the filter housingwithout any major modifications to the outer housing of the filter.

Once installed on the system or engine, the hot fluid (e.g., oil, fuelor coolant) will cause the sealants disposed on the metering openings tobe removed and the additive will then be free to flow out of themetering opening or openings.

While the invention has been described with reference to one or moreexemplary embodiments, it will be understood by those skilled in the artthat various changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof Therefore, it is intended that the invention notbe limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. A filter, comprising: a housing defining an inlet fluid opening andan outlet fluid opening, the inlet fluid opening and the outlet fluidopening defining a fluid path through the filter; a filter elementdisposed inside the filter housing, the filter element being disposed inthe flow path such that fluid flowing through the flow path must passthrough the filter element; and a dispersement device disposed withinthe housing, the dispersement device comprising a housing having atleast one chamber for an additive disposed within the at least onechamber, the dispersement device further comprises a metering openingthat is sealed with an oil soluble material the metering opening beingin fluid communication with the at least one chamber when the oilsoluble material is removed from the metering opening.
 2. The filter asin claim 1, wherein the additive is an additive composition comprises atleast one additive selected from the group consisting of basicconditioners, corrosion inhibitors, metal deactivators, antioxidants,dispersants, friction modifiers, oil stabilizers, pour pointdepressants, detergents, viscosity index improvers, anti-wear agents,extreme pressure additives, and mixtures thereof.
 3. The filter as inclaim 2, wherein the additive is an additive composition comprises abasic salt selected from the group consisting of lithium hydroxide,calcium carbonate, potassium carbonate, potassium bicarbonate, aluminumdihydroxy sodium carbonate, magnesium oxide, magnesium carbonate, zincoxide, sodium bicarbonate, sodium hydroxide, calcium hydroxide,potassium hydroxide, and mixtures thereof
 4. The filter as in claim 1,wherein the dispersement device is located substantially centrally inthe filter housing between the inlet fluid opening and the outlet fluidopening and the filter element.
 5. The filter as in claim 1, wherein thedispersement device is formed from an oil tolerable plastic.
 6. Thefilter as in claim 1, wherein the filter is an oil filter and theadditive composition is a liquid.
 7. The filter as in claim 1, whereinthe housing of the dispersement device has a circular configuration andan outer periphery of the housing of the dispersement device issubstantially similar to an outer periphery of the filter element andthe housing of the dispersement device further comprises a plurality ofdividing walls for defining the least one chamber and the filter is anoil filter and the additive is a liquid.
 8. The filter as in claim 7,wherein the housing of the dispersement device further comprises acentral opening aligned with the outlet fluid opening of the filter. 9.The filter as in claim 1, wherein the dispersement device furthercomprises a cap secured to the housing of the dispersement device, thecap being secured to the housing of the dispersement device after theadditive composition is placed within the at least one chamber of thedispersement device.
 10. The filter as in claim 9, wherein the cap ispositioned between the dispersement device and the filter element afterthe cap is secured to the housing of the dispersement device and themetering opening has a diameter of approximately 20/1000 of an inch.